INSTALLATION INSTRUCTIONS FOR PLASCORE L2550 LINER WALL

Transcription

1 INSTALLATION INSTRUCTIONS FOR PLASCORE L2550 LINER WALL The following information is provided by Plascore, Inc., as a general guideline for the installation of the L2550 Liner Wall System. This information should be reviewed prior to commencing installation. The information is intended to be a general guideline, and may not address specific, custom situations which may appear on any particular project. Please consult Plascore, Inc., for any specific details or design applications. This guideline assumes that the jobsite is clear and ready for the construction of cleanroom walls. The ceiling grid and the access floor, if applicable, are to be in place prior to beginning work on the wall system. Installation instructions for Plascore doors are not included in this document. Please reference Installation Instructions for Plascore Wide Stile Door or Installation Instructions for Plascore Narrow Stile Door. 1. UNCRATING, INSPECTION, AND INVENTORY A. All components of the wall system are clean room packaged for protection during shipping. All parts have been cleaned in the factory. B. Panels are shipped with a protective film, which should be left intact until the panels have been installed, and ready for final wipedown. C. Contractor should visually inspect crates as they unload off trucks. Crates may be unloaded with standard forklift equipment. Note any crate damage, and inspect crates with obvious damage. Compare label on crate with packing slip, which is attached to Bill of Lading. Notify Plascore of any discrepancies between part number and quantities on crate label and packing list. D. Crates should be stored where they are protected from moisture, humidity, and temperature extremes. See Cleaning Maintenance Storage Instructions for Plascore Walls for more information. E. Parts may be left in crates until required for installation. Note any damage on parts at this time, prior to installation. SHALLOW LINER WALL SYSTEM A1. INSTALLATION OF BATTEN AT FLOOR A. The battens have pre-drilled holes for attachment into the existing wall. Attachment hardware is to be furnished by contractor. Plascore does not provide the attachment hardware for the batten to the existing wall, due to installer preferences, local codes, and varying existing wall designs. When determining the hardware needs, know that the width of the opening in the batten is 0.40", which a bolt head must pass through. Web Installation Instructions - Plascore L2550 Wall.doc Page 1 of 8 Updated on 07/30/03

2 B. Remove the enclosure cap if it has been installed in the 1.75 Shallow Batten to be installed at the floor. C. Attach the 1.75 Shallow Batten (part number ) level with the floor. Do not tighten the batten against the wall completely leave it loosely attached. A2. TAKING MEASUREMENTS AND CUTTING COMPONENTS A. Measure the distance between the ceiling surface and the floor surface. Please note that this distance can vary along any given wall and measurements should be taken often and with care to ensure the proper sizing of components. Most of the components will be shipped at a nominal length, requiring to be cut to an exact length by the installer. This is to ensure proper fit and tight joints of the Plascore Liner Wall System. B. The panels have been sized in the factory to leave a 3/4" vertical gap between panels. To size the height of a panel, allow for a 1.25 gap between the panel and the floor surface and a 1.25 gap between the panel and the ceiling surface (for a total of 2.50 under the floor-to-ceiling measurement). C. The recommended option for cutting panels in the field is to use a circular saw with a fine-toothed carbide blade. D. To size the vertical battens, allow for the 1.75 Shallow Batten at the floor and at the ceiling (for a total of 3.50 under the floor-to-ceiling measurement). A3. INSTALLATION OF PANELS Plascore materials must be protected from exposure to water or other contaminants. Plascore materials must not be stored where they are exposed to the elements. A panel with protective film must not get wet at any time. Plascore materials should be stored at a temperature between 20 and 110 F. Storage at temperatures outside these limits may cause the protective film to be difficult to remove and/or it may leave residue on the panel. Plascore recommends that the protective film be removed within 6 months of purchase. It is Plascore s recommendation that the protective film be removed only 36 hours after the panel and film have reached F with relative humidity not to exceed 50%. Not following these guidelines may cause the protective film to be difficult to remove and/or it may leave residue on the panel. If the protective film leaves residue behind, notify Plascore immediately before proceeding. - taken from the Cleaning - Maintenance Storage Instructions for Plascore Walls. Please refer to the complete document for more information. A. Before installing a panel, peel back the protective film on both surfaces of the panel Web Installation Instructions - Plascore L2550 Wall.doc Page 2 of 8 Updated on 07/30/03

3 around all four edges approximately 1". Leave protective film intact on face of panel for protection until final wipedown occurs. B. To install a panel, set one end into the 1.75 batten attached to the existing wall at the floor. Hold the panel in place until the vertical battens can be installed. The adjacent panel can be slid into place behind this vertical batten to hold it in place. A4. INSTALLATION OF VERTICAL BATTENS A. Battens are typically installed on the same gridline as the cleanroom ceiling system overhead, which can act as a guideline during installation. B. After a panel is installed, install the 2.00 Shallow Batten vertically at the edge of the panel, centering the batten in the gap between the panels. Loosely attach the batten to the existing wall. C. After installing the adjacent panel, tighten down the batten screws to securely attach the batten to the wall. Typical spacing for the screws is 12" on center. (Consult the project architect or engineer for screw spacing for specific requirements.) Install the enclosure caps. D. Tighten down the batten screws to securely attach the 1.75 Shallow Batten at the floor level to the wall. A5. INSTALLATION OF BATTEN AT CEILING A. Attach the 1.75 Shallow Batten (part number ) flush with the top of the vertical battens. A6. INSIDE CORNERS A. Cut the panels back to end 1.50 from the corner. B. Two battens are used to create an inside corner for the Shallow Liner Wall System. Install a 1.75 Shallow Batten with the bent leg into the corner (see Detail FFO). Then, install a second 1.75 Shallow Batten, overlapping the bent leg on top of the first batten s bent leg. C. Install the enclosure caps in the battens. A7. OUTSIDE CORNERS A. Cut the panels back to end 1.25 from the corner. B. Two battens are used to create an outside corner for the Shallow Liner Wall System. Install a 2.00 Shallow Batten so that the outside batten wing is flush with the battens of the adjacent wall (see Detail FFP). Then, install a 1.75 Shallow Batten, butting the bent leg up to the backside of the 2.00 Shallow Batten. C. Install the enclosure caps in the battens. OFFSET LINER WALL SYSTEM Web Installation Instructions - Plascore L2550 Wall.doc Page 3 of 8 Updated on 07/30/03

4 B1. INSTALLATION OF OFFSET J-TRIM AT FLOOR A. Attachment hardware is to be furnished by contractor. Plascore does not provide the attachment hardware for the J-trim to the existing wall, due to installer preferences, local codes, and varying existing wall designs. B. Attach the Offset J-Trim (part number ) level with the floor, using the V- groove on the long leg of the offset J-trim as a location guide for the screws. B2. INSTALLATION OF OFFSET J-TRIM AT CEILING (if used) A. Attach the Offset J-Trim (part number ) to the existing wall, flush with the ceiling. Use the V-groove on the long leg of the offset J-trim as a location guide for the screws. B. If the Trimmed Wing Batten is being used at the ceiling, do not install the batten at this time. Continue with the sequence, with the installation of the batten detailed in Section B5. B3. TAKING MEASUREMENTS AND CUTTING COMPONENTS A. Measure the distance between the ceiling surface and the floor surface. Please note that this distance can vary along any given wall and measurements should be taken often and with care to ensure the proper sizing of components. Most of the components will be shipped at a nominal length, requiring to be cut to an exact length by the installer. This is to ensure proper fit and tight joints of the Plascore Liner Wall System. B. The panels have been sized in the factory to leave a 1.25" vertical gap between panels. To size the height of a panel, refer to the specific extrusion used at the ceiling level: a. Using an Offset J-Trim - allow for a.375 gap between the panel and the ceiling surface (for a total of under the floor-to-ceiling measurement). b. Using a Trimmed Wing Batten allow for a 1.13 gap between the panel and the ceiling surface (for a total of 1.13 under the floor-to-ceiling measurement). C. The recommended option for cutting panels in the field is to use a circular saw with a fine-toothed carbide blade. D. To size the vertical battens, allow for 0.50 at the Offset J-trim at the floor and 0.50 at the Offset J-trim at the ceiling (for a total of 1.00 under the floor-to-ceiling measurement) OR allow for 0.50 at the Offset J-trim at the floor and 1.13 at the Trimmed Wing Batten at the ceiling (for a total of 1.63 under the floor-to-ceiling measurement). Note: When using the Trimmed Wing Batten, the vertical batten extends up underneath the Trimmed Wing Batten. B4. INSTALLATION OF PANELS Web Installation Instructions - Plascore L2550 Wall.doc Page 4 of 8 Updated on 07/30/03

5 Plascore materials must be protected from exposure to water or other contaminants. Plascore materials must not be stored where they are exposed to the elements. A panel with protective film must not get wet at any time. Plascore materials should be stored at a temperature between 20 and 110 F. Storage at temperatures outside these limits may cause the protective film to be difficult to remove and/or it may leave residue on the panel. Plascore recommends that the protective film be removed within 6 months of purchase. It is Plascore s recommendation that the protective film be removed only 36 hours after the panel and film have reached F with relative humidity not to exceed 50%. Not following these guidelines may cause the protective film to be difficult to remove and/or it may leave residue on the panel. If the protective film leaves residue behind, notify Plascore immediately before proceeding. - taken from the Cleaning - Maintenance Storage Instructions for Plascore Walls. Please refer to the complete document for more information. C. Before installing a panel, peel back the protective film on both surfaces of the panel around all four edges approximately 1". Leave protective film intact on face of panel for protection until final wipedown occurs. D. To install a panel, set one end into the Offset J-trim attached to the existing wall at the floor. If an Offset J-Trim is used at the ceiling, bend the panel slightly to engage the top edge of the panel into the upper Offset J-trim. E. If a Trimmed Wing Batten is used at the ceiling, hold the panel in place until the vertical battens can be installed. The adjacent panel can be slid into place behind this vertical batten to hold it in place. B5. INSTALLATION OF VERTICAL BATTENS A. Battens are typically installed on the same gridline as the cleanroom ceiling system overhead, which can act as a guideline during installation. B. After a panel is installed, install the 2.00 T-Batten vertically at the edge of the panel, centering the batten in the gap between the panels. Loosely attach the batten to the existing wall. C. After installing the adjacent panel, tighten down the batten screws to securely attach the batten to the wall. Typical spacing for the screws is 12" on center. (Consult the project architect or engineer for screw spacing for specific requirements.) Install the enclosure caps. B6. INSTALLATION OF BATTEN AT CEILING (if used) A. Attach the Trimmed Wing Batten (part number ) flush with the ceiling surface, overlapping the tops of the vertical battens. Web Installation Instructions - Plascore L2550 Wall.doc Page 5 of 8 Updated on 07/30/03

6 B7. INSIDE CORNERS A. Cut the panels back to end 0.75 from the corner of the existing wall. Do not install the panels. B. Attach the Offset Inside Corner extrusion (part number ) in the corner, using the V-groove on the long leg of the extrusion as a location guide for the screws (see Detail P). C. Install the panels by sliding them into the Inside Corner extrusion. B8. OUTSIDE CORNERS A. Cut the panels back to end at the edge of the corner of the existing wall. Do not install the panels. B. Attach the Offset Outside Corner extrusion (part number ) in the corner, using the V-groove on the long leg of the extrusion as a location guide for the screws (see Detail Q). C. Install the panels by sliding them into the Outside Corner extrusion. 7. FINAL INSPECTION AND WIPE-DOWN A. Remove protective film from panels only after all installation steps have been completed. B. Wipe down panels and extrusions and door leafs with an approved alcohol wipe. If any chemicals are to be utilized in the cleaning process, spot check with extra materials prior to use to insure that the finish of the wall system is not affected. C. Consult Plascore s Maintenance and Cleaning Guide or a Plascore representative for specific cleaning issues. 8. RECOMMENDED TOOLS Following is a list of tools recommended by Plascore to install its L2550 Liner Wall System. This may not be a comprehensive list. Experience with the system and general construction techniques may help to personalize the tool choice for each contracting crew. a) Soft Rubber Mallet b) Claw Hammer (to open Plascore crates) c) Circular Saw with Fine Toothed Carbide Blade d) Chop Saw or Miter Saw with Fine Tooth Carbide Blade e) Plunge Router with Double Fluted Carbide Tip Bit (Optional) f) Suction Cup Panel Holders g) Drill with appropriate bit to secure fasteners Web Installation Instructions - Plascore L2550 Wall.doc Page 6 of 8 Updated on 07/30/03

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